Hybrid Fluid Connector Design for Low Pressure Loss
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Solution Overview
Problem
Existing connectors for fluid lines and units face challenges in achieving optimal flow conditions and low pressure loss while maintaining structural strength, particularly due to material and production method limitations in metallic and plastic connectors.
Innovation Solution
A hybrid connector design featuring a plastic base part and a metal mandrel part with a larger inner cross section, allowing for a circumferentially sealed connection and optimized flow behavior, achieved through a combination of material selection and innovative mold core arrangements to promote laminar flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If metallic connectors are used to reduce wall thickness and increase inner cross section, then flow conditions improve, but production complexity and energy consumption increase due to higher working temperatures required for metal processing
Solution Approach 1:
The connector combines metal and plastic materials in a hybrid design where the metal mandrel provides the inner cross-section for optimal flow conditions while the plastic base part provides structural support. This composite approach allows achieving flow-optimized dimensions without requiring high-energy metal processing for the entire connector, thus reducing overall energy consumption and production complexity
Solution Approach 2:
The connector is divided into two separate parts: a metal mandrel part and a plastic base part. These segments are manufactured separately using appropriate processes (metal processing for the mandrel, injection molding for the base) and then assembled together. This segmentation allows each material to be processed under optimal conditions, reducing overall production complexity and energy consumption
2Ease of manufacture
If plastic connectors are used to simplify production through injection molding, then manufacturing ease improves, but wall thickness must increase to maintain structural strength, reducing inner cross section and worsening flow conditions
Solution Approach 1:
The hybrid connector uses metal for the mandrel part where a large inner cross-section is required for optimal flow conditions, while plastic is used for the base part where structural support is needed. This allows achieving both flow optimization and structural integrity without requiring excessive wall thickness throughout the entire connector
Solution Approach 2:
Different materials are applied to different parts of the connector based on local requirements: metal is used specifically in the mandrel area where flow optimization is critical, while plastic is used in the base part where structural support and manufacturing simplicity are prioritized. This local differentiation optimizes both flow conditions and production ease
3Loss of energy
If metallic connectors are used to reduce wall thickness, then inner cross section increases improving flow behavior, but material cost increases due to higher price of metal compared to plastic
Solution Approach 1:
The connector uses a composite design where only the critical mandrel part is made of expensive metal to achieve flow optimization, while the larger base part is made of inexpensive plastic. This reduces overall material cost compared to an all-metal connector while still achieving the desired flow behavior in the critical flow path
Solution Approach 2:
Metal material is applied locally only where flow optimization is critical (in the mandrel part with the inner channel), while plastic material is used in non-critical areas (the base part). This localized material selection achieves flow optimization with minimal use of expensive metal, reducing overall material cost
Data Source
Figure 1~2a
Figure 3~4a
Figure 5~7
AI summary
The invention relates to a connector (1) for fluid lines and fluid assemblies, comprising at least two connection areas (2, 3) for pipe or hose lines and comprising a transition area (4) between the connection areas (2, 3), wherein each connection area (2, 3) and the transition area (4) are passed through by an inner channel (20, 30, 40), and at least one connection area (3) is designed as a mandrel (6). In order to create such a connector (1), which ensures an optimal flow formation and low pressure loss for the fluid flowing through in the operating state while being produced in a favorable manner from a technological and a material usage perspective, maintaining a specified outer diameter (D7) for a line connection and ensuring a required strength, it is proposed that the connector (1) comprise at least two parts (5, 6) composed of different materials, namely a base part (5), which is composed of a first material and which forms at least the transition area (4), and at least a mandrel part (6), which is composed of a second, mechanically stronger material, comprises an inner flow channel (30), can be inserted with a base part connection area (11) into a receptacle area (41) formed in an inner channel (40) of the base part (5) so as to be sealed circumferentially, and comprise a shaft (7) for the line connection, wherein a channel section (42) of the base part (5), which connects in the transition area (4) to the receptacle area (41) of the inner channel (40) of the base part (5), has an inner cross-section which is not smaller than the inner cross-section of the flow channel (30) of the mandrel part (6).